EWM STICK 450 Operating Instructions Manual

Brand: EWM

Model: STICK 450

Category: Welding System

Type: Operating Instructions Manual

This manual is also suitable for

EWM STICK 450 - The EWM STICK 450 inverter welding machine is a portable device designed for STICK welding. It is suitable for use in environments with an increased electrical hazard, as it complies with VDE 0544 (EN 60974-1). With a welding current range of 350A to 450A, it is capable of handling a variety of welding tasks. The STICK 450 features a user-friendly logic control system that provides precise control over the welding parameters, ensuring optimal weld quality. It also supports remote controls for added convenience.

EWM HIGHTEC WELDING GmbH

Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach

Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244

Internet:

www.ewm.de ; E-mail: [email protected]

Operating Instructions

inverter

STICK-Schweißgeräte

from 350A to 450A,

portable

inverter

STICK 350

inverter

STICK 350 PWS

inverter

STICK 450

N. B. These operating instructions must be read before commissioning.

Failure to do so may be dangerous. Machines may only be operated by personnel who is

familiar with the appropriate safety regulations.

The machines bear the conformity mark - and thus comply with the

· EC Low Voltage Guideline (73/23/EEC)

· EC EMV Guideline (89/336/EEC)

(The CE Mark is only required in EC member states)

In compliance with VDE 0544 (EN 60974-1), the machines can be used in environments with

an increased electrical hazard.

Originaldokument

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - Konformitätserklärung

EU - conformity declaration

Déclaration de Conformidité de U.E.

Name des Herstellers:

Name of manufacturer:

Nom du fabricant:

EWM HIGHTEC WELDING GmbH

(nachfolgend EWM genannt)

(In the following called EWM)

(nommé par la suite EWM)

Anschrift des Herstellers:

Address of manufacturer:

Adresse du fabricant:

Dr.- Günter - Henle - Straße 8

D - 56271 Mündersbach – Germany

[email protected]

Hiermit erklären wir, daß das nachstehend

bezeichnete Gerät in seiner Konzeption und

Bauart sowie in der von uns in Verkehr ge-

brachten Ausführung den grundlegenden

Sicherheitsanforderungen der unten genannten

EG- Richtlinien entspricht. Im Falle von

unbefugten Veränderungen, unsachgemäßen

Reparaturen und / oder unerlaubten Umbauten,

die nicht ausdrücklich von EWM autorisiert sind,

verliert diese Erklärung ihre Gültigkeit.

We herewith declare that the machine described

below meets the standard safety regulations of the

EU- guidelines mentionned below in its conception

and construction, as well as in the design put into

circulation by us. In case of unauthorized changes,

improper repairs and / or unauthorized

modifications, which have not been expressly

allowed by EWM, this declaration will lose its

validity.

Par la présente, nous déclarons que la conception

et la construction ainsi que le modéle, mis sur le

marché par nous, de l´appareil décrit ci - dessous

correspondent aux directives fondamentales de

sécurité de la U.E. mentionnées ci- dessous. En cas

de changements non autorisés, de réparations

inadiquates et / ou de modifications prohibeés, qui

n´ont pas été autorisés expressément par EWM,

cette déclaration devient caduque.

Gerätebezeichnung:

Description of the machine:

Déscription de la machine:

Gerätetyp:

Type of machine:

Type de machine:

Artikelnummer EWM:

Article number:

Numéro d´article

Seriennummer:

Serial number:

Numéro de série:

Optionen:

Options:

keine

none

aucune

Zutreffende EG - Richtlinien:

Applicable EU - guidelines:

Directives de la U.E. applicables:

EG - Niederspannungsrichtlinie (73/23/EWG)

EU - low voltage guideline

Directive de la U.E. pour basses tensions

EG- EMV- Richtlinie (89/336/EWG)

EU- EMC guideline

U.E.- EMC directive

Angewandte harmonisierte Normen:

Used co-ordinated norms:

Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Teil 206

Hersteller - Unterschrift:

Signature of manufacturer:

Signature du fabricant:

Michael Szczesny , Geschäftsführer

managing director

gérant

05.2000

Table of contents Page

contents /1

Safety instructions................................................................................................................................Safety/1

For your safety ..................................................................................................................................Safety/1

Transport and set-up...............................................................................................................................Safety/3

Notes on the use of these operating instructions....................................................................................Safety/3

General .........................................................................................................................................AI/1

1 Technical data..................................................................................................................................... 1/1

2 Description of the machine................................................................................................................ 2/1

3 Function specification (logic control)............................................................................................... 3/1

3.1 Function specification (logic control) .......................................................................................... 3/1

3.2 Function sequence MMA welding............................................................................................... 3/2

3.3 Remote controls .........................................................................................................................3/3

4 Commissioning................................................................................................................................... 4/1

4.1 Setting up the welding machine.................................................................................................. 4/1

4.2 Mains connection........................................................................................................................ 4/1

4.2.1 Reconnecting the mains voltage 400/415V at the control transformer (PWS only)......... 4/1

4.3 Welding machine cooling system............................................................................................... 4/2

4.4 Workpiece lead........................................................................................................................... 4/2

4.5 Electrode holder connection (MMA welding).............................................................................. 4/2

5 Maintenance and care ........................................................................................................................ 5/1

6 Operating problems, causes and remedies..................................................................................... 6/1

6.1 Customer checklist..................................................................................................................... 6/1

7 Spare parts list.................................................................................................................................... 7/1

8 Circuit diagrams.................................................................................................................................. 8/1

Safety instructions

Safety/1

For Your Safety:

Observe accident prevention regulations.

Ignoring the following safety procedures can be fatal.

· Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.

· Protect eyes and face with protective visor.

Electric shocks can be fatal

· The machine may only be connected to correctly earthed sockets.

· Only operate with intact connection lead including protective conductor and safety

plug.

· An improperly repaired plug or damaged mains cable insulation can cause electric

shocks.

· The machine may only be opened by qualified and authorised personnel.

· Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2

minutes until capacitors are discharged.

· Always put down welding torch, stick electrode holder in an insulated condition.

Even touching low voltages can cause you to jump and lead to accidents, so:

· Safeguard yourself against falls, e.g. from a platform or scaffolding.

· When welding, operate earth tongs, torch and workpiece properly, not in ways for

which they are not intended. Do not touch live parts with bare skin.

· Only replace electrodes when wearing dry gloves.

· Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning.

· Do not breathe in smoke and gases.

· Ensure that there is sufficient fresh air.

· Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes

can be converted into poisonous phosgene by ultraviolet radiation.

Workpiece, flying sparks and droplets are hot

· Keep children and animals well away from the working area. Their behaviour is

unpredictable.

· Move containers with inflammable or exposive liquids away from the working area.

There is a danger of fire and explosion.

· Never heat explosive liquids, dusts or gases by welding or cutting. There is also a

danger of explosion if apparently harmless substances in closed containers are able to

build up excess pressure when they are heated.

Take care to avoid fire hazards

· Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying,

when parts are glowing or hot slag is present.

· A constant check must be kept on whether fire hazards have been created in the

working area.

· Highly inflammable objects, such as matches and cigarette lighters for example, must

not be carried in trouser pockets.

· You must ensure that fire extinguishing equipment - appropriate to the welding process

- is available close to the welding work area and that easy access is possible.

Safety instructions

Safety/2

Take care to avoid fire hazards

· Containers in which fuels or lubricants have been present must be thoroughly cleaned

before welding begins. It is not sufficient simply for the receptacle to be empty.

· After a workpiece has been welded, it must only be touched or brought into contact

with inflammable material when it has cooled down sufficiently.

· Loose welding connections can completely destroy protective conductor systems of

interior installations and cause fires. Before beginning welding work, ensure that the

earth tongs are properly fixed to the workpiece or welding bench and that there is a

direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage

· Wear suitable earmuffs or plugs.

· Ensure that other people who spend time in the working area are not inconvenienced

by the noise.

Secure gas cylinder

· Place shielding gas cylinders in the holders provided for them and secure with safety

chains.

· Take care when handling cylinders; do not throw or heat, guard against them toppling

over.

· When moving by crane, take off the gas cylinder from the welding machine.

Interference by electrical and electromagnetic fields is possible e.g. from the welding

machine or from the high-voltage pulses of the ignition unit.

· As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are

intended for use in industrial areas; if they are operated e.g. in residential environments

problems can occur in ensuring electromagnetic compatibility.

· The functioning of heart pacemakers can be adversely affected when you are standing

near the welding machine.

· Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the

welding location is possible.

· Other mains supply leads, trip leads, signal and telecommunications leads above,

under and near the welding device may be subject to interference.

Electromagnetic interference must be reduced to such a level that it no longer constitutes

interference. Possible reduction measures:

· Welding machines should be regularly maintained (see Sect. “Maintenance and care”)

· Welding leads should be as short as possible and run closely together on or near to the

ground.

· Selective shielding of other leads and equipment in the environment can reduce

radiation.

Repairs and modifications may only be carried out by authorised, trained, specialist

personnel.

The warranty becomes null and void in the event of unauthorised interference.

Our operating instructions will provide you with an introduction into the safe use of the

machine.

Therefore please read them closely and only start work when you are familiar with them.

Safety instructions

Safety/3

Transport and set-up

· Machines may only be moved and operated in an upright position.

· Before moving, pull out mains plug and place on the machine.

· Secure high-pressure shielding gas cylinder with safety chain to prevent it from

toppling over.

Environmental conditions:

The welding machine can be operated in a location where there is no risk of explosion at

· an ambient temperature of -10°C (plasma machines 0°C) to +40°C and

· a relative air humidity up to 50% at 40°C.

· where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or

substances etc., insofar as they do not occur during welding.

Examples of unusual operating conditions:

Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive

quantities of dust such as grinding dust etc., severe weather conditions, unusual conditions near

the coast or on board ship.

· When setting up the machine, ensure that air inlets and outlets are unobstructed.

The machine is tested to Protection Standard IP23, i.e.:

· Protection against penetration of solid foreign bodies Æ > 12mm,

· Protection against water spray up to an angle of 60° to the vertical.

Notes on the use of these operating instructions

These operating instructions are arranged in Sections.

To help you find your way around more quickly, in the margins you will occasionally see, in addition

to sub-headings, icons referring to particularly important passages of text which are graded as

follows depending on their importance:

(Note): Applies to special technical characteristics which the user must note.

(Warning): Applies to working and operating procedures which must be followed

precisely to avoid damaging or destroying the machine.

(Caution): Applies to working and operating procedures which must be followed

precisely to avoid endangering people and includes the “Warning” symbol.

Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet

points, e.g.:

· Insert plug of welding current lead into socket (Sect. 5, G2) and lock.

Meaning of the diagram descriptions:

e.g. (C1) means: Item C / Figure 1 in the respective Section

e.g. (Sect. 3, C1) means: in Section 3 Item C / Figure 1

General

AL/1

About this machine manufactured in inverter technology

Congratulations.

You have purchased a modern and efficient welding machine in inverter technology.

In contrast to conventional welding current sources, it does not operate with 50Hz but with a 50kHz

primary-switch transistor current source.

You can now exploit the advantages of this inverter technology:

· Less effort in changing to another workplace because the machine dimensions and weight are

substantially reduced.

· Lower current consumption and smaller mains ratings by higher efficiency (lower losses).

· No need for expensive compensating equipment by a high cos phi and a correspondingly

smaller reactive current draw from the mains.

· Functional safety by robust construction and highly integrated electronic circuitry.

· High control dynamics for the welding process. Therefore, excellent welding and fusing results

and absolute reproducibility of all welding parameters.

· Welding results independent of mains voltage fluctuations.

· Easy to service design by the use of modern, modular technology.

· Adjustable arcforcing to adapt to any stick electrode welding task.

· Pole exchange switch for flexible and rapid work even when the stick electrodes are changed.

1 Technical data

1/1

inverter

STICK 350

inverter

STICK 350 PWS

inverter

STICK 450

Adjusting range Welding

current / voltage

5 A / 20.2 V -

350 A / 34 V

5 A / 20.2 V -450 A /

38 V

Efficiency

91%

Welding current at

60% DC of electrode

350A 450A

Welding current at

100% DC of electrode

270A 350A

Load alternation

10min (60% DC

6 min. welding, 4min. break)

Open circuit voltage

109V 78V

Mains voltage ( tolerances )

3x400V (+ 20% to - 25% )

3x415V (+ 15% to - 25% )

Mains frequency

50 - 60Hz

Mains fuses, slow-blow

3 x 25 A 3 x 35 A

cos j

0,99

Ambient temperature

-10

° C to 40°C

Protection classification

IP 23

Insulation class

Dimensions L/W/H incl.

handle

550mm x 370mm x

520mm

550mm x 370mm x

590mm

550mm x 440mm x

520mm

Weight

48kg 60kg 62kg

Built to

VDE 0544 Part 1 (EN 60974-1)

In compliance with VDE 0544 (EN 60974-1), this welding machine can be used in environments with

an increased electrical hazard.

2 Description of the machine

2/1

Fig. 1: Front view

Inverter

STICK 350 PWS

A Carrying handle

B Main power switch

C Rubber feet

Hot

100

150

300A

200

250

D Hotstart current rotary dial

E Yellow LED, excess temperature

250

300A

100

150

200

F Potentiometer for adjusting the welding current

Hot

0.5

sec.

1.5

G Hotstart time rotary dial

RUTIL

CELL

BASISCH

H Arcforcing rotary dial

Pole changeover switch (

inverter

STICK 350 PWS only )

ONOFF

Changeover switch: Cableless remote control "ON/OFF"

(

inverter

STICK 350/450 KLR only)

J Remote control connection

K Welding current socket "-"

(negative polarity in pole changeover switch position "-",

inverter

STICK 350

PWS only)

L Welding current socket "+"

(positive polarity in pole changeover switch position "-",

inverter

STICK 350

PWS only)

3 Function specification

3/1

3.1 Function specification (logic control)

Fig. 2:

Logic control

Inverter

STICK 350 PWS

250

300A

100

150

200

Main current I

The main current I

can be adjusted infinitely from 5A to the maximum

welding current.

Hot

100

150

300A

200

250

Hotstart current

The hotstart device makes it possible to ignite and re-ignite critical stick

electrodes without difficulty. Hotstart current setting I

Hot

infinitely

adjustable from 5A to the maximum welding current

Hot

0.5

sec.

1.5

Hotstart time

The hotstart time t

Hot

is adjusted infinitely from 0sec. to 2sec.

Hotstart device

The hotstart device makes it possible to ignite and re-ignite critical

stick electrodes without difficulty. The hotstart current and time are also

externally adjustable with the remote control FR 35.

Signal light, excess temperature (yellow)

Indicates an excess temperature of the welding machine and

extinguishes when this has cooled. Excess temperature occurs when

the duty cycle is exceeded or if the ventilation slots are obstructed.

3 Function specification

3/2

RUTIL

CELL

BASISCH

Adjustable arcforcing :

Shortly before the electrode threatens to stick, the arcforcing device sets

an increased current designed to prevent the electrode from sticking. The

value of the current increase depends on the setting of the arcforce

potentiometer. Excellent welding results are achieved with all difficult types

of electrode by arcforcing.

"Far left" position: Low arcforcing

Þ smoother arc,

low current increase before the short-

circuit. Used with stick electrodes

enveloped with rutile.

"Centre" position: Medium arcforcing

Þ normal arc,

medium current increase before the

Short-circuit. Used for alkaline coated

stick electrodes.

"Far right" position: High arcforcing

Þ hard arc,

high current increase before the short-

circuit. Used with cellulose stick electrodes.

Functional specification Antistick:

If the stick electrode sticks in spite of the arcforcing device, the machine

automatically switches over to the minimum current within about 1 sec, so

that the annealment of the electrode is prevented.

If the antistick device has responded, check the welding current setting and

if necessary correct it.

Pole exchange changeover switch (

inverter

STICK 350 PWS only)

Position "-" means : negative welding voltage potential at

welding current socket

( - )

positive welding voltage potential at

welding current socket

( + )

Position "+" means : positive welding voltage potential at

welding current socket

( - )

negative welding voltage potential at

welding current socket

( + )

ONOFF

Changeover switch: Cableless remote control "ON/OFF"

(

inverter

STICK 350/450 KLR only)

Switch position ON welding current setting by remote control

Switch position OFF welding current setting on the welding machine

3 Function specification

3/3

3.2 Function sequence MMA welding

When the stick electrode has been struck, the arc ignites at the adjusted hotstart current I

Hot

and

welds with this current until the expiry of the hotstart time t

Hot

. The hotstart current then falls to

the adjusted main current I

and remains constant until welding is completed. (see process chart

below)

If the electrode sticks in the welding pool for longer than 1 sec, the antistick device comes into

effect. Check the welding current setting and correct according to the welding task.

Welding current

Hotstart current

Hot

Main current

Hotstart time

Fig. 3:

Process chart for stick electrodes - welding with the hotstart device

3 Function specification

3/4

3.3 Remote controls

Only the remote controls described in these operating instructions may be connected!

Plug the remote control into the remote control socket of the welding machine (Chap. 2, J)

and lock it only when the machine is switched off.

The remote control is detected automatically when the welding machine is switched on.

See the operating instructions of the remote control for detailed information.

Foot-operated remote control FR 21

Functions

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

Manual remote control FR 30

Functions

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

Manual remote control FR 30F

Functions

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

The welding current I

is adjustable in 2 ranges for this

(coarse/fine adjustment)

Features

· Large adjusting knob

Manual remote control FR 30 PWS

Functions

· Pole changeover switch to change the welding polarity.

The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

Commissioning:

· The pole changeover switch of the machine must be in position +.

3 Function specification

3/5

Manual remote control FR 30F PWS

Functions

· Pole changeover switch to change the welding polarity.

The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

The welding current I

is adjustable in 2 ranges for this (coarse/fine adjustment).

Commissioning:

· The pole changeover switch of the machine must be in position +.

Features

· Large adjusting knob

Cableless manual remote control FR 30 KL

Functions

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

Commissioning:

· The changeover switch of the welding machine must be in position ON (cableless

remote control active)

Features

· Welding current adjustment without connecting cable

Manual remote control FRA 40

Functions

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

· The machine can be switched from remote control FRA 40 (switch position up) to

another remote control (switch position down) with the changeover switch.

Commissioning:

· Adjust the measurement range of the welding current display to the maximum

current of the machine.

(DIP switch in the remote control, setting when supplied: 250A)

Features

· LED welding current display.

· 10-turn helical potentiometer for accurate setting of welding current.

· Connection facility for further remote controls.

Manual remote control Hotstart FR 35

Functions

· Remote control "ON/OFF" (changeover switch on the remote control).

· Hotstart current and hotstart time infinitely adjustable.

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current, i.e. regardless of the welding current selected on the machine.

Commissioning:

· The welding current I

is adjustable in absolute values from the minimum to the

maximum current depending on the welding current selected on the machine.

· Switch on the remote control.

Features

· Connection facility for remote control FRA 40.

When the FR35 is in use, the hotstart current and time must be set to

their minimum values on the welding machine.

4 Commissioning

4/1

4.1 Setting up the welding machine

Follow safety instructions on the opening pages entitled "For Your Safety".

· Set up the machine so that there is enough room to adjust the operating elements.

· Ensure that the machine is set up in a stable position and appropriately secured.

4.2 Mains connection

The operating voltage shown on the rating plate must be consistent with the mains voltage!

For mains fuse, please refer to the technical data (Chap. 1)!

· Insert mains plug of the switched-off machine into the appropriate socket.

4.2.1 Reconnecting the mains voltage 400/415V at the control transformer

(PWS only)

Follow safety instructions on the opening pages entitled "For Your Safety".

The Faston plug (arrow) must be set on the transformer according to the mains voltage.

· For 400V: Connect plug to pin 4 (works setting),

· For 415V: Connect plug to pin 6.

415V400V

Fig.: Control transformer

Machines delivered to countries with mains

voltages which deviate from the standard are

marked with the following labels:

Indication of the mains voltage (at the end of the

cable)

Mains voltage on delivery

(rear of the unit above the rating plate)

Netzanschluß-

spannung

Mains voltage

400V

c) Special voltages, for marking according to

reconnecting on site (enclosed with the operating

instructions)

After reconnecting for 415V,

· label c) must be taped over label b) and

· label a) must be removed from the end of the

cable.

230V 230V

400V 400V

415V 415V

460V 460V

500V 500V

___V ___V

460V

500V

400

415

00V

15V

(Art. No. label, see accessory list)

4 Commissioning

4/2

4.3 Welding machine cooling system

Observe the following to attain the optimum duty cycle of the power units:

· Ensure that the working area is adequately ventilated,

· Do not obstruct the machine’s air inlets and outlets,

· Metal parts, dust or other foreign bodies must not get into the machine.

4.4 Workpiece lead

Remove paint, rust and dirt from clamping and welding areas with a wire brush! Attach the

workpiece clamp in the immediate vicinity of the welding position! Structural parts, pipes,

rails etc. may not be used as return leads for the welding current if they are not the

workpiece themselves!

A perfect current connection must be ensured where welding benches and appliances are

concerned!

· Insert cable plug of the workpiece lead into the welding current socket "+" (Chap. 2, Item L) or

"+" (Chap. 2, Item M) and lock by turning to the right.

The polarity depends on the instructions of the electrode manufacturer.

4.5 Electrode holder connection (MMA welding)

· Insert cable plug of the stick electrode holder into the welding current socket "+" (Chap. 2, Item

) or "-" (Chap. 2, Item L) and lock by turning to the right.

The polarity depends on the instructions of the electrode manufacturer.

5 Maintenance and care

5/1

Under normal operating conditions these welding machines are largely maintenance-free and

require a minimum of care. However, a number of points should be observed to guarantee fault-

free operation of your welding machine. Among these are regular cleaning and checking, as

described below, depending on the level of contamination in the environment and the usage time of

the welding machine.

Cleaning, testing and repairing of the welding machines may only be carried out by

competent personnel. In the event of failure to comply with any one of the following tests the

machine must not be operated again until the fault has been rectified.

5.1 Cleaning

To do this, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG!

(Switching off or unscrewing the fuse is not adequate isolation).

Wait for 2 minutes until the capacitors have discharged. Remove the casing cover.

The individual components should be handled as follows:

· Current source Depending on the amount of dust, blow out current source using oil-and

moisture-free compressed air.

· Electronics, circuit boards Do not blow on electronic components with the compressed air

stream but suck clean using a vacuum cleaner.

5.2 Repetition test according to VDE 0702 and VBG 15

The following description of the repetition test is merely an extract from the detailed test

instructions. If required, a copy can be requested from us!

You are recommended to carry out a quarterly and an annual check. The annual test should also

be carried out after every repair. Test sequence:

Quarterly test:

· Visual check of correct condition

· Measurement of protective conductor resistance

Annual test:

· Visual check of correct condition

· Measurement of protective conductor resistance

· Measurement of insulation resistance following internal cleaning of the power source

· Measurement of the open circuit voltage

· Function test of the welding machine

5.2.1 Visual check of correct condition

The machine must be inspected for externally visible faults (without opening the machine). During

this inspection, attention must be paid, for example, to the following points:

· External faults in mains plug and mains cable, e.g. insulation faults, scorch or pressure marks.

· Defects in anti-kink protection and the strain relief of the connection lead, mains switch.

· Faults in welding leads, tube package, plug fixture, arc torch.

· Signs of an overload and improper use.

· Damage to stop points and casing.

· Improper interference and modifications.

· The type plate and warning symbol must be present and legible.

Die im Kapitel

"Wartung und Pflege" aufgeführten Hinweise, Richtlinien und Normen wurden

grundlegend überarbeitet und sind aus diesem G

rund nicht mehr gültig!

Die relevanten Hinweise, Richtlinien und Normen finden Sie in den

beiliegenden

Ergänzungsblättern "Allgemeine Hinweise zu 3 Jahre G

arantie", Art. Nr.: 099-000GAR-EWMxx.

Sollten die Dokumente nicht vorliegen, können diese über den autorisierten Fachhändler

angefordert werden!

Außerachtlassung kann lebensgefährlich sein!

The instructions, guidelines and standards given in the "Maintenance and Care" chapter have

been completely revised and are therefore no longer valid!

The relevant instructions, guidelines and standards can be found in the enclosed supplements

"General notes on the 3 year warranty",item no.: 099-000GAR-EWMxx.

If these documents are missing, they can be reque

sted from your authorised specialist dealer!

Not observing these instruc

tions can be potentially fatal!

Les consignes, directives et normes indiquées au chapitre « Maintenance et entretien » ont été

mises à jour et ne sont donc plus valables !

Vous trouverez les consignes, directives et normes applica

bles dans les additifs « Consignes

généra

les relatives

à la garantie de 3 an

s », à l´article : 099-000GAR-EWMxx.

Si vous ne possédez pas les documents, vous pouvez vous les procurer auprès de votre

revendeur autorisé !

Le non-respect des consignes peut représenter un danger de mort !

Le istruzioni, direttive e norme presenti nel capitolo „

Manutenzion

e e cura” sono state

completamente riviste e per questo motivo non sono più valide!

Le istruzioni, direttive e norme rilevanti le trovate nell'aggiornamento qui allegato “Is

truzioni

generali sui 3 anni di

garanzia”, Nr. Art.: 099-000GAR-EWMxx.

Se i documenti non fossero disponibili, possono

essere richiesti al rivenditore autorizzato!

L'inosservanza delle istruzioni può comportare pericolo di vita!

5 Maintenance and care

5/2

5.2.2 Measurement of protective conductor resistance

Measure between safety contact of the mains plug and metal parts which can be touched, e.g.

casing screws.

During measuring, the entire length of the machine’s connection lead, especially near the

connection points, must be moved.

The resistance must be < 0.1

W. The measurement must be performed using at least 200 mA.

5.2.3 Measurement of insulation resistance

The machine must be disconnected from the mains!

Open the welding machine and clean it carefully (as described below).

Switch on mains switch.

· Insulation resistance mains current circuit - casing: Measure from a connection of the

mains plug to the casing. The resistance must be > 2.5 M

· Insulation resistance welding current circuit - casing: Measure between a welding socket

and protective conductor. The resistance must be > 2.5 M

· Insulation resistance mains current circuit - welding current circuit: Measure from a

connection of the mains plug to a welding current socket. The resistance must be > 5.0 M

5.2.4 Measurement of open circuit voltage

(according to EN 60974-1 / VDE 0544 T1)

6u8F

10nF

0...5k

Meqsurement circuit for peak values

Input

0k2

1k0

Diode similar 1N 4007

Connect the measuring circuit to the

welding current sockets as shown in Fig. 1.

The voltmeter must indicate the mean

value. Adjust the potentiometer from 0k

W to

W during the measurement.

The measured voltage must not deviate

from that specified on the rating plate (U

)

by more than 10%.

5.2.5 Function test of the welding machine

Carry out a function test depending on the type of machine.

5.3 Repair work

Repair and maintenance work may only be performed by qualified personnel.

In all service matters, always consult your dealer.

Return deliveries of defective equipment subject to warranty may only be made through your

dealer.

When replacing parts, use only original spare parts.

When ordering spare parts, the machine type, serial number and item number of the machine, as

well as the type description and item number of the spare part must be quoted.

If maintenance or repair work is carried out on this machine by personnel who are not trained and

authorised to undertake such work, the right to claim under the warranty lapses.

6 Operating faults, causes and remedies

6/1

All machines are subjected to strict manufacturing and final inspection procedures. If, despite this,

something fails to work at any time, please check machine using the following process chart. If

none of the fault elimination procedures described leads to the correct functioning of the machine,

please inform your authorised dealer.

Customer checklist

Switch on machine at the mains

switch

Yes

Machine is operative (fan running) No

··

Mains supply interrupted

··

Mains plug not inserted

··

Mains plug wrongly connected

··

Mains fuse faulty

··

Mains switch faulty

··

Excess temperature, yellow LED lights

(allow machine to cool)

Yes

Welding current No

··

Electrode holder or workpiece lead not

connected

Yes

Good welding properties No

··

Wrong material composition

··

Electrodes and workpiece leads

misconnected (follow manufacturer’s

instructions for electrodes)

··

Electrode not clean, incorrect switch

position PWS +/-.

Yes

Remote control functions No

··

Remote control plug not connected to the

machine

··

Remote control or cable defective

7 Spare parts list

7/1

Fig. 1, front

Designation Type

STICK 350 STICK 350 PWS STICK 450

1 Main switch

B2N-A-F15-B

D200-F15-B-SI

074-000279-00001

094-000525-00000

Switch knob

094-001814-00000

2 Rotary dial

Æ23mm / 2523060

074-000315-00000

Rotary dial cover

Æ23mm / 4123002

074-000315-00001

Rotary dial arrow

indicator

Æ23mm / 4223002

074-000315-00002

3 Rotary dial

Æ31mm / 2531060

074-000234-00000

Rotary dial cover

Æ31mm / 4131002

074-000234-00001

Rotary dial arrow

indicator

Æ31mm / 4231002

074-000234-00002

Changeover

switch:

000100.2901 - 044-001939-00000 -

(KLR units only) 1631/1pole OFF 094-001898-00000 - 094-001898-00000

5 PCB connector

board

EB 3 040-000408-00000

6 Socket built-in

DIXBE/70-95qmm 074-000232-00000 074-000517-00000

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EWM STICK 450 Operating Instructions Manual

Brand: EWM

Model: STICK 450

Category: Welding System

Type: Operating Instructions Manual

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